Base Material Conveying Device Diameter Measurement Correction

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Solution Overview

Problem

Existing base material conveying devices face challenges in precisely measuring the diameter of a base material wound on a roll due to noise in measurement results from non-contact diameter sensors, and errors in initial diameter and thickness values used for calculation.

Innovation Solution

A base material conveying device that includes an unwinding roll, a conveyor, a conveying distance meter, a diameter sensor, and a controller with a low-pass filter to smooth and correct diameter measurements, using initial diameter and thickness values to calculate accurate winding diameter values by compensating for delays and noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a non-contact type diameter measurement sensor is used to measure the diameter of the base material wound on the roll, then the measurement can be performed without contact, but the measurement result includes noise and lacks precision

Engineering Contradiction:

Improvenon-contact measurementVSAvoiddiameter measurement precision

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The system uses feedback by continuously measuring the diameter multiple times and comparing the measured values with the calculated values to identify and correct measurement errors. The correction amount derived from the difference between measured and calculated diameters is fed back to improve subsequent measurements, resolving the precision issue while maintaining non-contact operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent introduces an intermediary approach by using the calculated diameter (based on unwinding distance and initial diameter) as a reference to correct the noisy sensor measurements. This intermediary calculated value acts as a mediator between the noisy sensor data and the true diameter, enabling precise measurement without direct contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If the diameter is calculated from the conveying distance of the base material, then contactless calculation is achieved, but errors in initial diameter and thickness values prevent precise calculation

Engineering Contradiction:

Improvediameter calculation precisionVSAvoidcalculation accuracy

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The system employs feedback by using the sensor measurements (even though noisy) to derive a correction amount that compensates for errors in the initial diameter and thickness values. This correction is applied to the calculated diameter, thereby improving calculation accuracy and reliability without requiring perfect initial parameters.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces direct reliance on mechanical measurement parameters (initial diameter and thickness) with a hybrid approach that substitutes sensor-based feedback information. This substitution allows the system to overcome errors in mechanical parameter specifications by using actual operational data to correct the calculations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If multiple diameter measurements are taken during conveyance to improve precision, then more data is obtained, but noise in the measurement results increases

Engineering Contradiction:

Improvediameter measurement precisionVSAvoidmeasurement noise

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The system uses feedback to distinguish between useful measurement variations and noise. By comparing multiple measurements with the calculated diameter and analyzing the deviation patterns, the system identifies the true signal from the noise, thereby improving precision without being adversely affected by the increased noise from multiple measurements.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent converts the harmful effect of noise into a benefit by using the statistical properties of the noisy measurements. The noise, when aggregated through multiple measurements and processed via feedback comparison with calculated values, provides information about measurement deviations that can be corrected, thereby turning noise into a source of correction data.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS11939179B2Base material conveying device, printing apparatus, coating apparatus and base material roll diameter obtaining method

Publication Date: 2024.03.26 SCREEN HOLDINGS CO LTD

AI summary

The measured winding diameter values Ds1(d) corresponding to the conveying distance d are measured by measuring the diameter of the printing medium M wound on the unwinding roll 71 by the diameter sensor 77. The measured winding diameter values Ds1(d) are smoothed by the low-pass filter to extract the smoothed winding diameter values Ds_avg1(d). By calculating the value of the diameter based on the initial diameter value Do1, the thickness value Tm and the conveying distance of the printing medium M, the calculated winding diameter values Dc1(d) are calculated. An operation of calculating the difference Ddiff1(d) between the calculated winding diameter value Dc1(d) and the smoothed winding diameter value Ds_avg1(d) while compensating for the delay by the low-pass filter is performed whereby the differences Ddiff1(d) are calculated. The calculated winding diameter value Dc1(d) are corrected by the differences Ddiff1(d).